8/10/2019 AWS - Evaluating Welded Joints, Test 2003

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TEST METHODS

FOR EVALUATING

WELDED JOINTS

Prepared by theWelding Handbook

Chapter Committeeon Test Methods forEvaluating WeldedJoints:

D. E. Williams, ChairConsulting Engineer

D. M. BeneteauCenterline (Windsor)

Limited 

 J. A. ClarkWestinghouse Electric

Corporation

B. H. LyonsConsultant 

E. R. SampsonConsultant 

R. F. WaiteConsultant 

Welding HandbookVolume 1 CommitteeMember:

D. W. DickinsonThe Ohio State University

Contents

Introduction 2

Testing for Strength 3

Hardness Tests 18

Bend Tests 22

Fracture ToughnessTesting 23

Fatigue Testing 34

Corrosion Testing 39

Creep and RuptureTesting 42

Testing of ThermalSpray Applications 43

Weldability Testing 46

Conclusion 54

Bibliography 54

SupplementaryReading List 56

C H A P T E R 9

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TEST METHODS FOR EVALUATING WELDED JOINTS 3

Test results must therefore be carefully interpreted andapplied. As each laboratory test provides only a limitedamount of information on the properties of weldedjoints, most weldments are evaluated using several tests.Each test provides specific data on the serviceability of the weldment. The properties evaluated by testinginclude strength (e.g., ultimate tensile strength, yield

strength, shear strength), tensile ductility (e.g., elonga-tion and reduction of area), bend test ductility, tough-ness (e.g., fracture toughness, crack arrest toughness,and Charpy V-notch toughness), fatigue, corrosion, andcreep. The scope of the testing is either defined as partof the investigation or specified in the relevant code orstandard, depending on the application.

Testing should be performed on samples that reflectthe heat treatment condition used in service. However,the topic of the aging of steel specimens often arises intesting welded joints. In this context, aging is a degas-sing treatment at room temperature or a slightly ele-vated temperature. For example, the American Welding

Society’s filler metal specification for carbon steel fluxcored arc welding electrodes,2 as well as some weldingcodes such as Structural Welding Code—Steel , AWSD1.1:2000,3, 4  permit the aging of tension test speci-mens at 200°F to 220°F (93°C to 104°C) before testing.However, other codes such as the Bridge Welding Code,ANSI/AASHTO/AWS D1.5-96,5  do not permit agingfor weld procedure qualification tests.

The welding process can introduce hydrogen into theweld metal, mostly from water that is disassociatedunder the high temperature of the arc. The hydrogendiffuses out over time but may introduce anomalies intotensile test results. These can sometimes be seen as

“fisheyes” (small pores surrounded by a round, brightarea on the fracture surface of tension tests of steelwelds) even though normal cup-and-cone fracture maybe observed, if tested only days later, and the yieldstrength, ultimate strength, and impact test results willremain unchanged. Such low-temperature aging is per-mitted because it does not change the metallurgical

2. American Welding Society (AWS) Committee on Filler Metals,Specification for Carbon Steel Electrodes for Flux Cored Arc Weld-ing , ANSI/AWS A5.20, Miami: American Welding Society.3. American Welding Society (AWS) Committee on Structural Weld-ing, 2000, Structural Welding Code—Steel, AWS D1.1:2000, Miami:American Welding Society.

4. At the time of the preparation of this chapter, the referenced codesand other standards were valid. If a code or other standard is citedwithout a date of publication, it is understood that the latest editionof the document referred to applies. If a code or other standard iscited with the date of publication, the citation refers to that editiononly, and it is understood that any future revisions or amendments tothe code or standard are not included; however, as codes and stan-dards undergo frequent revision, the reader is encouraged to consultthe most recent edition.5. American Welding Society (AWS) Committee on Structural Weld-ing, 1996, Bridge Welding Code,  ANSI/AASHTO/AWS D1.5-96,Miami: American Welding Society.

structure; it simply quickens the diffusion of hydrogenfrom the weldment. With this one exception, weldmenttesting is typically performed using specimens that rep-resent the heat treatment condition of the weldment asit will be used in service.

The various testing methods used to evaluate theexpected performance of welded and brazed joints andthermal spray applications are examined in this chapter.The description of each method includes a discussion of the property being tested, the test methods used, theapplication of results, and, most importantly, the man-ner in which these results relate to welded joints. Anoverview of weldability testing is also presented.6

This chapter makes frequent reference to the Stan-dard Methods for Mechanical Testing of Welds, ANSI/ AWS B4.0 and AWS B4.0M,7  and Standard Methodsand Definitions for Mechanical Testing of Steel Prod-ucts, ASTM A 370.8  The latest edition of these stan-dards should be consulted for more information onthe testing and evaluation of welded joints. In addi-

tion, the American National Standard Safety inWelding, Cutting, and Allied Processes, ANSI Z49.1,9

should be consulted for rules regarding health and safetyprecautions.

TESTING FOR STRENGTH

The design of nearly every component and structureis based on minimum tensile properties. As welded

joints contain metallurgical and often compositionaldifferences that result from the welding process, theeffects of these changes on the mechanical properties of the weldment must be assessed. Some strength tests,such as tension tests, measure tensile strength directly,while others, such as the peel test, verify that the weld isas strong as the base metal. The various techniques usedto evaluate the strength of weldments are discussedbelow.

6. Weld soundness is evaluated using the nondestructive examinationmethods described in Chapter 14, Vol. 1 of the Welding Handbook,9th ed., Miami: American Welding Society.7. American Welding Society (AWS) Committee on Mechanical Test-

ing of Welds,  Standard Methods for Mechanical Testing of Welds,ANSI / AWS B4.0, Miami: American Welding Society; American Weld-ing Society (AWS) Committee on Mechanical Testing of Welds, Stan-dard Methods for Mechanical Testing of Welds, AWS B4.0M, Miami:American Welding Society.8. American Society for Testing and Materials (ASTM) Subcommit-tee A01.13, Standard Test Methods and Definitions for Mechanical Testing of Steel Products, ASTM A 370, West Conshohocken, Penn-sylvania: American Society for Testing and Materials.9. American National Standards Institute (ANSI) Accredited StandardsCommittee Z49, Safety in Welding, Cutting, and Allied Processes,ANSI Z49.1, Miami: American Welding Society.

YRIGHT 2003; American Welding Society, Inc. Document provided by I HS Licensee=ConocoPhillips WAN/5919206100, User=,11/18/2003 21:26:48 MST Questions or comments about this message: please callthe Document Policy Group at 1-800-451-1584.

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